MAX

Designed to make work safer for its people, and to increase the efficiency of the aluminium production process, MAX, is also a world-first.

Aluminium smelters are a new frontier for autonomous vehicles. The magnetic fields, indoor and outdoor traffic, dust and heat levels in the operations present a set of new challenges, and none of the available autonomous vehicles had been able to meet their specific requirements.

The prototypeMAX 01 was developed by Aluminium Technology Solutions teams, and first went to work at the Dunkerque aluminium smelter in northern France. After a successful pilot there in 2014, we are now developing an industrial version of the technology, names MAX ANODE, which is set for first deployment this year.

The choice of name, MAX is linked to its key properties: being Modular, Autonomous and able to cross (X) over between different parts of the plant.

Bringing MAX to life

Aluminium smelters are a new frontier for autonomous vehicles. The magnetic fields, indoor and outdoor traffic, dust and heat levels in the operations present a set of new challenges, and none of the available autonomous vehicles had been able to meet their specific requirements.

The prototypeMAX 01 was developed by Aluminium Technology Solutions teams, and first went to work at the Dunkerque aluminium smelter in northern France. After a successful pilot there in 2014, we are now developing an industrial version of the technology, names MAX ANODE, which is set for first deployment this year.

The choice of name, MAX is linked to its key properties: being Modular, Autonomous and able to cross (X) over between different parts of the plant.

A partnership of human and machine

Though MAX is unmanned, people are essential to its operation. Yet the arrival of autonomous technology can create uncertainty among an industrial workforce.

MAX is designed to complement existing manned vehicles and the employees who receive the material it is transporting. And although people aren’t physically in the vehicle, they’ll play an essential role in controlling and maintaining MAX and in planning its itinerary.

Technologically, MAX is controlled by the Logistic Integrated Solution for Aluminium Fleet Supervision system: the “LISA FS”. This system provides real-time updates on the status of each vehicle, inventory levels and storage locations, to determine where MAX should be, and when.

MAX ANODE

Once testing was complete, the prototype was considered a resounding success, and was showcased last year at the Autonomous Machines World conference in Berlin.

Rio Tinto has since been developing the industrial version – MAX ANODE – working in partnership with ECA Group, which specialises in robotics, automated systems and industrial processes. It’s set for deployment at Aluminium Dunkerque in 2019.

Smelter of the Future

MAX is but one part of the AP Technology TM smelter of the future. called also the “4.0 smelter”.

The aim is to develop a smelter model that is attractive for employees, safe, profitable, uses cutting-edge technology, and that taps into synergies generated by new collaborations with external partners.

The research is focusing on areas including processing, sensors, modelling, control systems, data analytics and automation. The aim is that this work will lead to smelters with zero emissions and improved working conditions, and that it brings about new opportunities for market differentiation.